A digitized welding torch
By acquiring and analyzing multi-dimensional data throughout the entire lifecycle of digital welding guns in real time, the limitations of parameter control and insufficient data acquisition in traditional resistance welding guns have been solved, thereby improving welding quality and stability and meeting the high precision and intelligent requirements of modern manufacturing.
Patent Information
- Application Number
- CN202610303720.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-03-13
- Publication Date
- 2026-06-16
AI Technical Summary
The limitations of traditional resistance welding clamp parameter control and insufficient data acquisition lead to unstable welding quality, making it difficult to meet the high precision and intelligent requirements of modern manufacturing.
By adopting a digital welding clamp that integrates a data acquisition unit, mathematical modeling and control unit, it can realize full-cycle multi-dimensional data acquisition and real-time analysis, dynamically optimize welding parameters, and establish a welding data traceability system.
Improve the stability and adaptability of welding quality, enable online prediction and equipment health status assessment, and provide comprehensive data support.
Smart Images
Figure CN122210195A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of resistance welding clamp technology, and more particularly to a digital welding clamp. Background Technology
[0002] Resistance welding pliers are specialized tools that apply pressure to metal workpieces using electrodes and then pass electricity to form a weld. As core equipment in automated welding production lines in industries such as automotive manufacturing and construction machinery, their welding quality directly affects the connection strength between workpieces and the reliability of the product. Furthermore, with the development of Industry 4.0 and intelligent manufacturing, robotic resistance welding has become the mainstream application. However, traditional resistance welding pliers struggle to meet the high-precision, traceable, and intelligent production demands of modern manufacturing, and suffer from the following technical shortcomings: 1. Limitations of parameter control: Traditional resistance welding clamps rely on preset fixed parameters and cannot adjust parameters in real time according to the workpiece material, surface condition and dynamic changes during the welding process (such as electrode wear, temperature fluctuations, etc.). This can easily lead to defects such as burn-through of thin plate workpieces and failure to fuse thick plate workpieces. 2. Insufficient data collection and utilization: Traditional resistance welding clamps can only monitor a small number of key parameters, and the data is mostly collected at a single point in an instant. There is a lack of full-cycle, multi-dimensional data recording of the welding process, which makes it impossible to predict the welding quality and perform predictive maintenance of the equipment status.
[0003] Meanwhile, when welding workpieces at different tilt angles, the resistance welding clamp installed on the robotic arm has a large range of adjustment and poor precision in order to ensure the vertical arrangement between the electrode and the workpiece. This can easily affect the overall welding quality of the workpiece, resulting in poor stability and reliability.
[0004] Therefore, there is an urgent need for a resistance welding clamp that can achieve continuous data monitoring and accurate data acquisition, in order to solve the shortcomings of the traditional resistance welding clamp in actual operation. Summary of the Invention
[0005] This application proposes a digital welding clamp that can continuously monitor and accurately collect data during the welding process and adjust the corresponding parameter changes in real time, thereby achieving high welding quality for the workpiece. This solves the limitations of traditional resistance welding clamps in parameter control and the problems of insufficient data collection and utilization.
[0006] To achieve the above objectives, this application adopts the following technical solution: a digital welding clamp, comprising a mechanical actuator fixedly mounted on a robotic arm for performing welding processes on workpieces and a human-machine interface unit for controlling the mechanical actuator. The mechanical actuator includes a welding clamp body fixedly mounted on the robotic arm. A power cylinder assembly is fixedly mounted on one side of the bottom of the inner cavity of the welding clamp body, and an electrode assembly for conducting current and performing welding processes on the drive shaft of the power cylinder assembly is fixedly mounted. Meanwhile, a replaceable electrode cap is fixedly mounted at one end of the power cylinder assembly. Under the driving action of the power cylinder assembly, the electrode cap on the electrode assembly can directly make extrusion contact with the surface of the workpiece. A transformer electrically connected to the electrode assembly is fixedly mounted on the top of the right end of the welding clamp body, and the transformer continuously provides current output to the electrode assembly for performing welding processes on the workpiece. A data acquisition unit is fixedly installed on the right side of the top of the welding clamp body. The data acquisition unit includes an acquisition module and a data processing submodule that integrate pressure, temperature, and cooling water flow. The acquisition module and data processing submodule are used to acquire signal parameters of welding pressure, cooling water temperature, and flow, and to perform preliminary processing on the acquired data. A pressure and displacement acquisition module is used to indirectly monitor the welding penetration depth. The pressure and displacement acquisition module includes a displacement sensor fixedly installed on one side of the top of the power cylinder group, and the displacement sensor is used to monitor the displacement of the electrode assembly driven by the power cylinder group. An integrated current and voltage acquisition module is used to acquire the secondary current and secondary voltage of the transformer. The integrated current and voltage acquisition module includes a secondary voltage feedback module and a secondary current feedback module fixedly installed on the left side of the top of the welding clamp body. The human-computer interaction unit includes a mathematical modeling and control unit consisting of a microprocessor and a storage module. The storage module can pre-store various mathematical models, while the microprocessor executes mathematical model algorithms to achieve data processing and control decisions. The mechanical execution unit and the human-machine interaction unit are connected via a communication unit fixedly installed on the transformer side end face, forming a closed-loop digital system of acquisition-modeling-control-feedback between them. This enables precise perception, intelligent decision-making, and dynamic control of the welding process, including: 1. Achieve high-precision synchronous acquisition of multi-dimensional data throughout the entire welding process. 2. Real-time analysis of collected data using mathematical models enables online prediction of welding quality and assessment of equipment health status; 3. Based on the mathematical model, the welding parameters are dynamically optimized, which improves the welding adaptability and quality stability of the resistance welding gun under different working conditions; 4. A comprehensive welding data traceability system has been established, providing effective data support for production quality control.
[0007] Furthermore, the human-machine interaction unit adopts a touch screen operating interface for parameter setting, process status display, and abnormal alarm prompts.
[0008] Furthermore, the communication unit includes two types: an Ethernet communication module and a bus communication module. The Ethernet communication module is used for data connection and feedback between the mechanical execution unit and the human-machine interaction unit, including uploading welding data logs and receiving remote control commands. The bus communication module is used for data connection and feedback between the displacement sensor, secondary voltage feedback module, and secondary current feedback module on the mechanical execution unit and the data acquisition unit.
[0009] Furthermore, the electrode assembly includes a T-shaped bracket fixedly mounted on the drive shaft of the power cylinder group. A welding electrode is pinned to the end of the inner cavity of the T-shaped bracket, and one end of the welding electrode extends to the other side of the inner cavity of the T-shaped bracket and is connected to a first elastic element fixedly mounted thereon. A positioning sleeve is slidably sleeved on one side of the outer surface of the welding electrode, and the right end of the positioning sleeve is connected to it through a second elastic element movably sleeved on the outer surface of the welding electrode.
[0010] Furthermore, the outer side of the positioning sleeve is designed as a U-shaped structure, and a set of pressure balls is provided at the upper and lower ends of the U-shaped structure. Initially, under the elastic force of the second elastic element, one end of the positioning sleeve protrudes from the left end of the welding electrode. Then, when the electrode assembly is driven by the power cylinder group to make contact with the workpiece surface, the pressure balls can first make contact with the workpiece surface.
[0011] Furthermore, initially, under the elastic force of the first elastic element, the central axis of the welding electrode coincides with the central axis of the drive shaft on the power cylinder assembly. When the pressure balls on the positioning sleeve come into contact with the workpiece surface: If the end of the welding electrode is arranged perpendicularly to the workpiece, the force on the upper and lower ends of the positioning sleeve is uniform. As the power cylinder group continuously applies pressure, the positioning sleeve contracts in the opposite direction and compresses the second elastic element until the end of the welding electrode comes into contact with the surface of the workpiece. If the end of the welding electrode is not perpendicular to the workpiece, the force on the upper and lower ends of the positioning sleeve is uneven. During the continuous pressure application by the power cylinder group, the positioning sleeve is forced to tilt the welding electrode to the corresponding side and compress the first elastic element in the corresponding direction until the upper and lower ends of the positioning sleeve come into contact with the surface of the workpiece, and the end of the welding electrode is perpendicular to the workpiece.
[0012] Furthermore, the right end of the positioning sleeve is provided with an electromagnetic structure, which forms an electrical feedback connection with the two sets of pressure balls: When both sets of pressure balls are in contact with the workpiece surface, the electromagnetic structure is not triggered, making the elastic strength of the first elastic element greater than that of the second elastic element. When there is no contact or only one set of pressure balls with the workpiece surface, the electromagnetic structure is triggered, and the reverse force generated by the second elastic element in cooperation with the electromagnetic structure is greater than the elastic force of the first elastic element, thereby ensuring that the electrode assembly can operate normally and stably under different working conditions.
[0013] The beneficial effects of this invention are as follows: 1. The digital welding clamp provided in this application enables high-precision synchronous acquisition of multi-dimensional data throughout the entire welding process by setting up mechanical actuators and their linkage structures. The acquired data is analyzed in real time through mathematical models, thereby realizing online prediction of welding quality and assessment of equipment health status. This improves the welding adaptability and quality stability of the resistance welding clamp under different working conditions. At the same time, a complete welding data traceability system is established, providing effective data support for production quality control.
[0014] 2. The digital welding clamp provided in this application addresses the issue that when the end of the welding electrode is not perpendicular to the workpiece, the force on the upper and lower ends of the positioning sleeve is uneven. During the continuous pressure application by the power cylinder, the positioning sleeve is forced to tilt the welding electrode to the corresponding side and compress the first elastic element in the corresponding direction until the upper and lower ends of the positioning sleeve come into contact with the surface of the workpiece, thereby ensuring that the end of the welding electrode is perpendicular to the workpiece. This further improves the welding quality of the resistance welding clamp on the workpiece. Attached Figure Description
[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort: Figure 1 This is a simplified system diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the welding clamp body of the present invention; Figure 3 This is a front view of the welding clamp body of the present invention; Figure 4 This is a schematic diagram of the electrode assembly of the present invention; Figure 5 This is a front view of the electrode assembly of the present invention.
[0016] In the figure: 1-Welding clamp body, 2-Power cylinder group, 3-Electrode assembly, 4-Displacement sensor, 5-Transformer, 6-Data acquisition unit, 7-Secondary voltage feedback module, 8-Secondary current feedback module, 9-Communication unit, 10-T-shaped bracket, 11-Welding electrode, 12-First elastic element, 13-Positioning sleeve, 14-Second elastic element, 15-Pressure ball. Detailed Implementation
[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0018] like Figures 1-3 As shown, a digital welding clamp includes a mechanical actuator fixedly mounted on a robotic arm for performing welding processes on workpieces and a human-machine interface unit for controlling the mechanical actuator. The mechanical actuator includes a welding clamp body 1 fixedly mounted on the robotic arm. A power cylinder group 2 is fixedly mounted on one side of the bottom of the inner cavity of the welding clamp body 1, and an electrode assembly 3, which conducts current and performs welding processes on the workpiece, is fixedly mounted on the drive shaft of the power cylinder group 2. Meanwhile, a replaceable electrode cap is fixedly mounted on one end of the power cylinder group 2. Under the driving action of the power cylinder group 2, the electrode cap on the electrode assembly 3 can directly make extrusion contact with the surface of the workpiece. A transformer 5, which is electrically connected to the electrode assembly 3, is fixedly mounted on the top of the right side of the welding clamp body 1, and the transformer 5 continuously provides current output to the electrode assembly 3 for performing welding processes on the workpiece. A data acquisition unit 6 is fixedly installed on the right side of the top of the welding clamp body 1. The data acquisition unit 6 includes an acquisition module and a data processing submodule that integrate pressure, temperature and cooling water flow. The acquisition module and the data processing submodule are used to acquire signal parameters of welding pressure, cooling water temperature and flow, and to perform preliminary processing on the acquired data. A pressure and displacement acquisition module is used to indirectly monitor the welding penetration depth. The pressure and displacement acquisition module includes a displacement sensor 4 fixedly installed on one side of the top of the power cylinder group 2, and the displacement sensor 4 is used to monitor the displacement of the electrode assembly 3 driven by the power cylinder group 2. An integrated current and voltage acquisition module is used to acquire the secondary current and secondary voltage on the transformer 5. The integrated current and voltage acquisition module includes a secondary voltage feedback module 7 and a secondary current feedback module 8 fixedly installed on the left side of the top of the welding clamp body 1. The human-computer interaction unit includes a mathematical modeling and control unit consisting of a microprocessor and a storage module. The storage module can pre-store various mathematical models, while the microprocessor executes mathematical model algorithms to achieve data processing and control decisions. The mechanical execution unit and the human-machine interface unit are connected via a communication unit 9 fixedly installed on the side end face of transformer 5, forming a closed-loop digital system of data acquisition, modeling, control, and feedback between them. This enables precise perception, intelligent decision-making, and dynamic control of the welding process, including: 1. Achieve high-precision synchronous acquisition of multi-dimensional data throughout the entire welding process. 2. Real-time analysis of collected data using mathematical models enables online prediction of welding quality and assessment of equipment health status; 3. Based on the mathematical model, the welding parameters are dynamically optimized, which improves the welding adaptability and quality stability of the resistance welding gun under different working conditions; 4. A comprehensive welding data traceability system has been established, providing effective data support for production quality control.
[0019] In this technical solution, the human-machine interaction unit adopts a touch screen operation interface for parameter setting (such as workpiece material, thickness, target welding strength, etc.), process status display (real-time parameter curves, model output results, etc.), and abnormal alarm prompts (quality exceeding standards, equipment failure, etc.).
[0020] In this technical solution, the communication unit 9 includes two types: an Ethernet communication module and a bus communication module. The Ethernet communication module is used for data connection and feedback between the mechanical execution unit and the human-machine interaction unit, including uploading welding data logs and receiving remote control commands. The bus communication module is used for data connection and feedback between the displacement sensor 4, the secondary voltage feedback module 7, and the secondary current feedback module 8 on the mechanical execution unit and the data acquisition unit 6.
[0021] like Figure 2 , Figure 4 as well as Figure 5 As shown, in this technical solution, the electrode assembly 3 includes a T-shaped bracket 10 fixedly mounted on the drive shaft of the power cylinder group 2. A welding electrode 11 is pinned to the end of the inner cavity of the T-shaped bracket 10, and one end of the welding electrode 11 extends to the other side of the inner cavity of the T-shaped bracket 10 and is connected to the first elastic member 12 fixedly mounted thereon. A positioning sleeve 13 is slidably sleeved on one side of the outer surface of the welding electrode 11, and the right end of the positioning sleeve 13 is connected to it through a second elastic member 14 movably sleeved on the outer surface of the welding electrode 11.
[0022] like Figure 4 , Figure 5As shown, in this technical solution, the outer part of the positioning sleeve 13 is set as a U-shaped structure, and a set of pressure balls 15 are respectively provided at the upper and lower ends of the U-shaped structure. Initially, under the elastic force of the second elastic element 14, one end of the positioning sleeve 13 protrudes from the left end of the welding electrode 11. Then, when the electrode assembly 3 is driven by the power cylinder group 2 to make contact with the workpiece surface, the pressure balls 15 can first make contact with the workpiece surface.
[0023] like Figure 2 , Figure 4 as well as Figure 5 As shown, in this technical solution, initially, under the elastic force of the first elastic element 12, the central axis of the welding electrode 11 coincides with the central axis of the drive shaft on the power cylinder group 2. When the pressure ball 15 on the positioning sleeve 13 comes into contact with the workpiece surface: If the end of the welding electrode 11 is arranged perpendicularly to the workpiece, the force on the upper and lower ends of the positioning sleeve 13 is uniform. As the power cylinder group 2 continuously applies pressure, the positioning sleeve 13 contracts in the opposite direction and compresses the second elastic element 14 until the end of the welding electrode 11 comes into contact with the surface of the workpiece. If the end of the welding electrode 11 is not perpendicular to the workpiece, the force on the upper and lower ends of the positioning sleeve 13 is uneven. During the continuous pressure applied by the power cylinder group 2, the positioning sleeve 13 is forced to tilt the welding electrode 11 to the corresponding side and compress the first elastic element 12 in the corresponding direction until the upper and lower ends of the positioning sleeve 13 come into contact with the surface of the workpiece, and the end of the welding electrode 11 is perpendicular to the workpiece.
[0024] In this technical solution, the right end of the positioning sleeve 13 is provided with an electromagnetic structure, which forms an electrical feedback connection with the two sets of pressure balls 15: When both sets of pressure balls 15 are in contact with the workpiece surface, the electromagnetic structure is not triggered, making the elastic strength of the first elastic element 12 greater than that of the second elastic element 14. When there is no contact or only one set of pressure balls 15 with the workpiece surface, the electromagnetic structure is triggered, and the reverse force generated by the second elastic element 14 in cooperation with the electromagnetic structure is greater than the elastic force of the first elastic element 12, thereby ensuring that the electrode assembly 3 can operate normally and stably under different working conditions.
[0025] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A digital welding clamp, comprising a mechanical actuator and a human-machine interface unit, characterized in that: The mechanical execution unit includes a welding clamp body (1), a power cylinder group (2) is fixedly installed on one side of the bottom of the inner cavity of the welding clamp body (1), and an electrode assembly (3) is fixedly installed on the drive shaft of the power cylinder group (2). At the same time, an electrode cap is fixedly installed at one end of the power cylinder group (2), and a transformer (5) that is electrically connected to the electrode assembly (3) is fixedly installed on the top of the right side end of the welding clamp body (1). A data acquisition unit (6) is fixedly installed on the right side of the top of the welding clamp body (1). The data acquisition unit (6) includes an acquisition module and a data processing sub-module, a pressure and displacement acquisition module, and an integrated current and voltage acquisition module. The acquisition module and data processing submodule are used to acquire signal parameters of welding pressure, cooling water temperature and flow rate, and to perform preliminary processing on the acquired data; The pressure and displacement acquisition module includes a displacement sensor (4) fixedly installed on one side of the top of the power cylinder group (2), and the displacement sensor (4) is used to monitor the displacement of the electrode assembly (3) driven by the power cylinder group (2); The integrated current and voltage acquisition module includes a secondary voltage feedback module (7) and a secondary current feedback module (8) fixedly installed on the left side of the top of the welding clamp body (1). The human-computer interaction unit includes a mathematical modeling and control unit consisting of a microprocessor and a storage module. The storage module pre-stores mathematical models, while the microprocessor executes mathematical model algorithms to achieve data processing and control decisions. The mechanical execution unit and the human-machine interaction unit are connected by a communication unit (9) fixedly installed on the side end face of the transformer (5), forming a closed-loop digital system of acquisition-modeling-control-feedback between the mechanical execution unit and the human-machine interaction unit.
2. The digital welding clamp according to claim 1, characterized in that, The human-machine interaction unit adopts a touch screen interface for parameter setting, process status display, and abnormal alarm prompts.
3. The digital welding clamp according to claim 2, characterized in that, The communication unit (9) includes two types: an Ethernet communication module and a bus communication module. The Ethernet communication module is used for data connection and feedback between the mechanical execution unit and the human-machine interaction unit, while the bus communication module is used for data connection and feedback between the displacement sensor (4), the secondary voltage feedback module (7), and the secondary current feedback module (8) on the mechanical execution unit and the data acquisition unit (6).
4. The digital welding clamp according to claim 1, characterized in that, The electrode assembly (3) includes a T-shaped bracket (10) fixedly mounted on the drive shaft of the power cylinder group (2). The end of the inner cavity of the T-shaped bracket (10) is pinned to a welding electrode (11), and one end of the welding electrode (11) extends to the other side of the inner cavity of the T-shaped bracket (10) and is connected to a first elastic element (12) fixedly mounted thereon. A positioning sleeve (13) is slidably sleeved on one side of the outer surface of the welding electrode (11), and the right end of the positioning sleeve (13) is connected to it through a second elastic element (14) movably sleeved on the outer surface of the welding electrode (11).
5. The digital welding clamp according to claim 4, characterized in that, The positioning sleeve (13) is externally configured as a U-shaped structure, and a set of pressure balls (15) are provided at the upper and lower ends of the U-shaped structure respectively. Initially, under the elastic force of the second elastic element (14), one end of the positioning sleeve (13) protrudes from the left end of the welding electrode (11).
6. The digital welding clamp according to claim 5, characterized in that, Initially, under the elastic force of the first elastic element (12), the central axis of the welding electrode (11) coincides with the central axis of the drive shaft on the power cylinder assembly (2). When the pressure ball (15) on the positioning sleeve (13) comes into contact with the workpiece surface: If the end of the welding electrode (11) is arranged vertically with the workpiece, the upper and lower ends of the positioning sleeve (13) are subjected to uniform force. As the power cylinder group (2) continuously applies pressure, the positioning sleeve (13) contracts in the opposite direction and compresses the second elastic element (14) until the end of the welding electrode (11) comes into contact with the surface of the workpiece. If the end of the welding electrode (11) is not vertically arranged with the workpiece, the force on the upper and lower ends of the positioning sleeve (13) is uneven. During the continuous pressure applied by the power cylinder group (2), the positioning sleeve (13) is forced to tilt the welding electrode (11) to the corresponding side and compress the first elastic element (12) in the corresponding direction until the upper and lower ends of the positioning sleeve (13) come into contact with the surface of the workpiece, and the end of the welding electrode (11) is vertically arranged with the workpiece.
7. The digital welding clamp according to claim 6, characterized in that, The right end of the positioning sleeve (13) is provided with an electromagnetic structure, which forms an electrical feedback connection with the two sets of pressure balls (15): When both sets of pressure balls (15) are in contact with the workpiece surface, the electromagnetic structure is not triggered, so that the elastic strength of the first elastic element (12) is greater than the elastic strength of the second elastic element (14). When there is no contact between the workpiece surface and only one set of pressure balls (15), the electromagnetic structure is triggered, and the reverse force generated by the second elastic element (14) in cooperation with the electromagnetic structure is greater than the elastic force of the first elastic element (12).